Solution grade pvc-copolymers prepared by suspension polymerization exhibiting enhanced light stability and low haze

ABSTRACT

A METHOD IS PROVIDED FOR THE SUSPENSION OF POLYMERIZATION OF &#34;SOLUTION GRADE&#34; VINYL CHLORIDE/VINYL ACETATE COPOLYMER EXHIBITING ENHANCED ULTRAVIOLET LIGHT STABILITY AND RELATIVELY LOW HAZE. THE METHOD COMPRISES POLYMERIZING VINYL CHLORIDE AND FROM ABOUT 1 TO 25% BY WEIGHT VINYL ACETATE IN THE PRESENCE OF A CATALYTIC AMOUNT OF A &#34;HOT CATALYST&#34;, FROM ABOUT 0.03 TO ABOUT 0.3% OF A METHYL CELLULOSE SUSPENDING AGENT AND EITHER BENZENE OR TOLUENE. THE REACTION IS CONDUCTED AT A TEMPERATURE OF FROM 0*C. T O 90*C. THE HOT CATALYST HAS A TEN HOUR HALF-LIFE TEMPERATURE OF LESS THAN 60*C.

United States Patent @ffice 3,558,578 SOLUTION GRADE PV'CCOPOLYMERS PRE- PARED BY SUSPENSION POLYMERIZATION EXHIBITIN G ENHANCED LIGHT STABILITY AND LOW HAZE 3,558,578 Patented Jan. 26, 1971 Consistently clear, high-gloss coatings have been obtained by the use of these cleaner resins. They are conventionally pigmented by conventional techniques. These resins are widely used as maintenance coatings for protecting steel, coil coatings to prevent corrosion of sheet before Paul Kraft, Yonkers, William F. Keller, Dobhs Ferry, fabrication and as prime and top coats. They are used as and slegflled Altshel3 asslgllols t0 can coatings, as liners, as coatings in prefinished wood f g g Company New York: 3 generally plywood for exterior and interior use, as coatig gg g i gg g 4 1968 Ser No 782 733 ings for textiles to provide coated fabrics with supple,

o i n s Q I The portion of the term of the patent subsequent to Soft plush i and drape demanqed fashions and May 12, 1987, has been di l i d Wear characteristics, as paper and foil coat ngs; they find I t, Cl, (josf /24, 15/30 use for decorative markings in inks and llnings for hot US. Cl. 26087.1 10 Claims drink cups. As indicated above, they additionally serve as top coats for highly plasticized vinyl compositions and for rubber in polyurethane foams. ABSTRACT OF THE DISCLOSURE 15 It has been well known and conventional in the art to A method is provided for the suspension of polymeriprelpare vmyl chlende/vlnyl acetate eepelymere and e zation of solution grade vinyl chloride/vinyl acetate Po ymers by SOIPHOH techn'lques to P e resms havmg copolymer exhibiting enhanced ultraviolet light stability exceptional clarity when dissolved 1n a suitable solvent. and relatively low haze. The method comprises polymer- Heretoforea the P e grade Teslne have e P izing vinyl chloride and from about 1 to by weight P r 111 a Solvent whlch 18 an expenslve q a vinyl acetate in the presence of a catalytic amount of a qumng slolvent recpvery and addltlonal Capltal Invest catalyst, from about 003 to about 03% of a ment. So vent loss in the recoverysteps further reduces methyl cellulose suspending agent and either benzene or e eiffieleney the operetlon- Whlle suspenslon P toluene. The reaction is conducted at a temperature of 25 eneatlen teehmques have been long keown, are Deere from 0 C. to 90 C. The hot catalyst has a ten hour easlly run e e less eostlyi suspenslon Pelymenzed haIHife temperature of less than C. copolyiners invariably contain contaminants, i.e., residual suspending agents and catalyst residue. These contaminants contribute to solution haze when the resin is dis- The present invention relates to the preparation of i in convelhtif h l as mehhyl isobultyl etone and met et etone. en suc resin so uselution grade Polyvinyl chloride copolymers by we tions are coated im the substrate and dried, these consion Polymerization technique" More Particularly thls taminants cause film cloudiness which is undesirable be- Venti9n relates to the Preparation of light table Vinyl cause of reduced coating effectiveness, film continuity,

chlgnde/vmyl f copcllymers .charaitellzed 1 the corrosion resistance, salt spray resistance, water resistance ablhly to flerm f eg c ear eoatmg so moms, y and the like, and exhibit relatively poor ultraviolet light pension po ymeriza ion. Stabilit T term Solution in reference, to this CategOIX In azcordance with the provisions of the present invenf i l e e g i g si $2 82; tion, solution grade resins which yield clear solutions in mg ese resms' a oweve 1 conventional solvents and exhibit other ro erties ex- 4 P P utilized to identify the pOlgl'IierlZalilold procedure in tthat hibited. by typihal solution h resins prepared via the ifiZQZZiZZ 32 113211 2231.d ai higfi liiifi 2211 12.; expensae 5 polynagraatwn g g Prepared by sus ension tec ni ues uti izin met ce u ose as a sus substantially free from catalyst residue and substantially i agent aqhohreactivf catalgsh and benzene or free e contaminants Producing a and low m 45 toluene as a chain transfer agent. These resins also extiona so ution ra e resins.

vinyl chloride homopolymers, the advantages which they By the use 5 the term howeacfive catalyst is meant afford justify the additional expense involved. These resthose catalysts having a 10 hour hamhfe at a tempera ins are permanently internally plasticized thereby elim- 0 tum below inating plasticizer extraction and migration problems with 5 Exemplary of the hot catalysts are: aothzobis (OHM t plasticizer content is not critical small quantities of plas- 'g g gg ggz i' ggf g f ii zfi gz g agent is fiz gg i ggfi g i izzz iifi i a g: tended both methyl cellulose per se and its derivatives, as methyl isobutyl ketone and film formation occurs simfor example hydroxypfopylmethyl cellulose Whlch are ply by Solvent evaporation from the solution, requiring conventionally known in the art. Methyl cellulose prodlower temperatures, shorter times and making possible nets are derlved from and have the polymene'backbolfe in-field applications with ambient temperature drying. of cellulose, 21 natllf a1 Carbohydrate that cqntalns a basle Very thin coatings are most uniformly applied from sofepeatlng Structure of anhydroglucose unlts- The basle lution systems, thereby providing additional advantages. structure for methyl cellulose is as follows:

FORMULAI H TH (131120 CH3 "I PII (H3113 Q Q (Loni H H H 11 OCH; H H H 0 0 0H H 11 OH LHaOCHs H OCH: N CHzOH wherein N represents the number of repeating units. ered in order to effect the necessary etficiency required in Methyl cellulose is conventionally prepared by swelling commercial practice. Both the suspension polymerization cellulose fibers obtained from cotton linters or wood technique and the solution technique defined above are pulp by a caustic soda solution to produce alkali celluwell known in the art.

lose. The alkali cellulose is subsequently treated with The process of the present invention is particularly methyl chloride yielding the methyl ether of cellulose. applicable to the preparation of vinyl chloride/vinyl ace- The fibrous reaction product is purified and ground to a tate copolymers. These copolymers generally contain fine uniform powder or granule. Also intended to be withfrom about 1 to about by weight vinyl acetate and in the definition of methyl cellulose are such derivatives preferably from about 13 to about 20% by weight vinyl as hydroxypropyl methyl cellulose. This derivative is acetate. The preferred copolymer range indicated progenerally prepared by reacting propylene oxide with 10 vides exceptional coating grade resins. It should be noted methyl cellulose to obtain hydroxypropyl substituents on also that the preferred copolymer range indicated above the anhydroglucose units. The substituent group Provides an exceptionally g od balance of Properties As is well known, polyvinyl chloride homopolymer exhibits OCH2 CH(OH)CH3) poor solubility in coating solvents such as methyl ethyl contains a secondary hydroxyl on the second carbon. Such ketone, methyl isobutyl ketone and the like. Vinyl acetate products generally possess Varying ratios of such hydroxy increases the solubility but detracts from the toughness propoxyl substitution to methoxyl substitution. These of the vinyl polymer. The range specified provides an exmaterials are commercially available. The hydroxy procellent balance of solubility and toughness.

pyl methyl cellulose has the formula set forth below: In preparing the vinyl chloride/vinyl acetate copolymers FORMULA II The methyl cellulose derivatives are available commerin the process of the present invention, the vinyl chloride cially under the name Methocel a reglstered trademark and vinyl acetate are generally used such that the vinyl of Dow Chemical Company. acetate is present in an amount of from about 13 to about The chain transfer agent employed in the process of 17% based on weight. The hot reactive catalysts of this this invention is benzene or toluene and can be defined invention are generally used in an amount from about as an aromatic hydrocarbon containing from 6 to 7 car- 0.01 to about 0.3% by weight based upon the weight of bon atoms inclusive. the monomer and are preferably used in an amount from In order to place the present invention in the proper about 0.07 to about 0.11. The methyl cellulose suspendperspective, a definition of conventional suspension polyming agent is generally used in an amount from about 0.03 erization and conventional solution polymerization is to about 0.3% by weight based upon monomer. This mabelieved desirable. terial is generally available at the 1% aqueous solution Suspension polymerization refers to the polymerization and is utilized as such for convenience. It is preferred, of monomer dispersed in a suspension medium which is however, that this methyl cellulose suspending agent be a non-solvent for both the monomer and the polymer, utilized in an amount of from about 0.09 to about 0.15% generally water utilizing normally a monomer soluble by weight based upon monomer. The aromatic hydroinitiator. Suspension polymerization takes place within carbon chain transfer agent as utilized in this invention is the monomer phase containing the polymer solution inigenerally used in an amount of from about 0.5 to about tiator. However, the use of the suspending medium assists 6.0% by weight based upon the weight of the monomer. in the dissipation of heat of reaction and therefore the It is preferred, however, that this transfer agent be utipolymerization reaction is easier to control. Suspension liZed in an amount of from about 0,8 to abo t 3,()% polymerization is generally accomplished by dispersing It should be noted that the methyl cellulose suspending the monomer in the suspending medium either by conagent, the hot reactive Catalyst and the aromatic y stant agitation or by the use of a suspending agent or Carbon chain transfer agent are all critical in this invenboth. Various conventional suspending agents are known tioh in that if these agents are not used as specified, P yto the art. These known suspending agents include gelamer solutions of relatively low haze and enhanced ultratin, hydroxy methyl cellulose, hydroxy ethyl cellulose, hy- Violet stability at e not ned. droxy propyl cellulose, carboxy methyl cellulose, talc, The polymerization reaction of this invention is generclay polyvinyl alcohol d h h ally conducted at a temperature of from about 40 C to In distinction solution polymerization is a process about although it is preferred to Conduct th s r which requires the use of an inert liquid, which is a solaction at temperatures of f about C. to about vent for the monomer compound used in forming the poly- While the Polymerization reaction is generally mer, hi h Solvent may or may not b a Solvent fo h 55 stantially complete after about seven hours, the time of prepared polymer. The catalyst or initiator if used is Polymetilatioh generally runs from about n t tw lve monomer soluble. Solution polymerization has the adhours to insure adequate Polymerizationvantage that the solvent as in suspension polymerization The Polymerization t on o this invention is conassists in the dissipation of heat. The average molecular ducted at superetmospherie Pressure This Pressure is weight of the polymers as prepared by the use of solu- 70 veniently the vapor pressure of the vinyl chloride vinyl u po1ymerization are generally lower h those hacetate monomer composition at the specific temperature tamed by the use of other polymerization techniques and p y For p at a mixture of Parts th1s method can be effective in the production of low of Vinyl chloride to 15 Parts Vinyl acetate atfeet a Pressure molecular weight vinyl halide polymers. However, this Of approximately pounds per square inch. For conprocess has the drawback that the solvent must be recov- 75 venience this pressure temperature composition relationship will be denoted as autogeneous pressure. If desired, however, higher pressures can be utilized by subjecting the reaction to the artificial effects of an inert gas under pressure, such as nitrogen. Such high pressure techniques, however, require the use of specialized equipment and, accordingly, are not preferred.

Attempts to employ other suspending agents such as are conventionally used in suspension polymerization have resulted in resins which do not yield the desired characteristics typified by conventional solution grade resins. This is particularly true in respect to the haze values exhibited by coatings of such resins and stability to ultraviolet radiation. Similarly, the employment of conventional non-hot catalysts fail to produce the desired resins as did the employment of chain transfer agents other than the aromatic hydrocarbons, benzene and toluene. I

In Table I following is illustrated conventional and hot catalyst as defined within the terms of this invention, illustrating both structure and temperature half-life at ten hours.

and heated for specific periods of time. The oil bath should be continuously stirred and constant temperatures should be maintained, preferably within plus or minus 0.1 C. The tubes are thereafter withdrawn from the oil bath periodically and are cooled rapidly by immersion in ice water. The contents are analyzed for undecomposed catalyst. Iodiometric and infrared techniques can be employed for the analysis. The iodiometric technique consists of treatment of the organic catalyst solution with an inorganic iodide such as sodium or potassium iodide or aqueous hydriodic acid, followed by tritration of the liberated iodine with standard sodium thiosulfate solution. Catalysts resistant to iodide reduction can be assayed through the use of infrared differential analysis. In this analysis, standard molar solutions of each peroxide (0.025 m. to 0.4 m.) are prepared and standard curves of absorption vs. concentration and distance vs. concentration are obtained. The residual catalyst concentration can then be read directly from the spectra of partially decomposed samples.

TABLE L-STRUCTURE AND HALF-LIFE:(10 hour) TEMPERATURE [Conventional and Hot Catalysts] Temperature, 0., half-life Catalyst 1 Structure 10 hours 0 O (1) Benzoyl peroxide (]-OO(3 72 CH CH3 (2) Vazo H;C-( )--N=N-C-( JH3 JN 0N 2,2-azobisisobutyronitrile (3) Lauroyl peroxide H O(CH2)1o- -0-O-i (CH2)mCH3 62 E 0 CH CH CH (4) Azo-52 CHCH2CN=NC E-CHZCH 52 1130 JN JN CH3 a,a-Azobis(a,'y-dirnethylvaleronitrile) CH 0 CH: (5) Lupersol-ll HQC(!,OO J-C ECH3 57 t-Butyl peroxypivalate H30 0 0 CH (6) IPP CHO( JOOQ Z JOCH 46 Diisopropyl peroxydicarbonate H3O CH3 CH3 CH2 (7) Azo-33 C-OHz( JN=N-C JCHZC CHQ 33 H30 OOHs lN ON OCH:

a,a'-AZObiS (ayy-dimethyl ymethoxyvaleronitrile) 1 Catalysts 1-3 Conventional; Catalysts 4-7 Hot Catalysts.

The ten hour half-life temperature of hot catalysts can EXAMPLE 1 be determined by preparing a benzene solution of the catalyst to be evaluated at a concentration of 0.2 mole of catalyst per liter of solvent. Ten milliliters of the catalyst solution are pipetted into test tubes suitably drawn for rapid sealing. The tubes preferably used are 16 by 150 millimeters. The filled tubes which preferably have about 5 milliliters of air space remaining are flushed with dry nitrogen, are sealed and immersed in a silicone oil bath An autoclave was charged with the following ingredients:

0.20 parts of Dow 1242 Methocel, which is commercial tmethylcellulose;

0.25 part sodium bicarbonate (as buffer);

10.0 parts toluene transfer agent;

0.14 part tertiary butyl peroxypival ate hot catalyst;

320 parts deionized water.

The autoclave was sealed and evacuated and 124 parts of vinyl chloride and 26 parts of vinyl acetate were charged. The reaction was conducted for a period of 14 hours at a temperature of about 60 C. At the end of the reaction time, the polymer sample was recovered, washed in cold water and dried. This example was repeated identically, except that in place of t-butyl peroxypivalate catalyst, an equivalent amount of a 2,2-azobisisobutyronitrile catalyst was utilized. The sample was additionally recovered and dried. The two samples were dissolved in to about 0.3% by weight based upon weight of monomer of a hot catalyst having a ten hour half-life temperature of less than 60 C., from about 0.03 to about 0.3% by weight based upon monomer of a methyl cellulose suspending agent and benzene or toluene as a chain transfer agent, at a temperature of from about C. to about 90 C.

2. The method of claim 1 wherein the hot catalyst is utilized in an amount of from about 0.07 to about 0.11% by weight, the methyl cellulose suspending agent is utimethyl isobutyl ketone to a concentration of 20%. Simi- 10 lized in an amount of from 0.09 to about 0.15% by larly, a sample of commercial solution grade vinyl chloweight and the chain transfer agent is toluene utilized in ride/vinyl acetate resin Of similar composition was diS- an amount of from about 0,8 to about 3 by weight. solved to a similar concentration. The three samples were 3, Th th d f l i 1 h i th olymerization evaluated for haze value by sight. Table below shows the i d t d t a temperature of f b t 45 t b t results of this determination. 75 C.

TABLE 4. The method of claim 1 wherein the hot catalyst utilized is a,a'-azobis (a,'y-dimethyl valeronitrile). cafalyst used MIBK HaZe 5. The method of claim 1 wherein the hot catalyst utim Example 13 Value by slght 20 lized is tertiary butyl peroxypivalate.

( t' ButylPeroXy clear, translucent'haze 6. The method of claim 1 wherein the hot catalyst PWalate Yalue range 15 2O- utilized is diisopropyl peroxydicarbonate. z 2':azoblslsobutyro' Shght haze shghtly 7. The method of claim 1 wherein the hot catalyst nltllle opaque'haze value utilized i 41, azobis (11,Y-dil116thY1 'y methoxyvalero- (3);..VYHH, Union Carrange 35. 25 nitri1e f Solunon 8. The method of claim 1 wherein the suspending agent Resm utilized is a methyl cellulose having the formula:

H OH CHgOCI-Is H OCH3 /l l l HO OCH: H H Hj/H O OOH3 H H A H H /\O-- \OH H \H H H OH 0 o (LHzOCHa I III (LCHa N JI-IZOH The three polymers were exposed to ultraviolet radiation for a period of from 1,000 to 1,300 hours and examined for color. Sample 2 above proved most stable. Samwherein N designates the number of repeating units.

9. The method of claim 1 wherein the methyl cellulose suspending agent has the formula:

wherein N designates the number of repeating units.

10. The method of claim 1 wherein the chain transfer agent is benzene.

References Cited UNITED STATES PATENTS 3,004,009 10/1961 Dell 26086.3 3,293,199 12/1966 Abercrombie 26017 3,388,110 6/1968 Kuhlkamp 26085.7 3,420,807 1/ 1969 Harrison 26092.8

(Other references on following page) 10 FOREIGN PATENTS JAMES A. SEIDLECK, Primary Examiner 1,493,610 7/1967 France 26087.1 C. A. HENDERSON, JR., Assistant Examiner OTHER REFERENCES Schildknecht, C. E., Polymer Processes, Interscience Publishers, N.Y. (1956), vol. X, pp. 176, 180. 5 260-17, 32.8, 80

US. Cl. X,R. 

